Binder composition for rechargeable lithium battery, and electrode and rechargeable lithium battery including the same

Abstract

 The present invention relates to a binder composition for a rechargeable lithium battery including a cross-linked composition of polyacrylic acid and polyvinyl alcohol, wherein the polyacrylic acid comprises one or more non-cross-linked acid groups that are substituted with an alkali metal cation or ammonium cation or combinations thereof.

Description

BACKGROUND OF THE INVENTION

Field of the Invention

[0001] This disclosure relates to a binder composition for a rechargeable lithium battery, and an electrode and a rechargeable lithium battery including the same.

Description of the Related Art

[0002] Lithium rechargeable batteries have recently drawn attention as a power source for small portable electronic devices. They use an organic electrolyte solution and thereby, have twice or more the discharge voltage than a conventional battery using an alkali aqueous solution, and accordingly, have high energy density.

[0003] The rechargeable lithium battery is fabricated by injecting electrolyte into an electrode assembly, which includes a positive electrode including a positive active material capable of intercalating/deintercalating lithium ions and a negative electrode including a negative active material capable of intercalating/deintercalating lithium ions.

[0004] For fabricating an electrode, a binder is required to provide adherence of the active material. A binder is also required for improving the cycle-life characteristics of a battery and for the stability of the electrode along with the high adherence.

SUMMARY OF THE INVENTION

[0005] One aspect of the present invention provides a binder composition for a rechargeable lithium battery being capable of improving the stability of an electrode and providing excellent cycle-life characteristics.

[0006] Another aspect of the present invention provides an electrode for a rechargeable lithium battery including the binder composition.

[0007] Yet another aspect of the present invention provides a rechargeable lithium battery including the binder composition.

[0008] According to one aspect of the present invention, a binder composition for a rechargeable lithium battery comprising a cross-linked composition of polyacrylic acid and polyvinyl alcohol, wherein the polyacrylic acid comprises one or more non-cross-linked acid groups that are substituted with an alkali metal cation or ammonium cation or combinations thereof, is provided.

[0009] According to another aspect of the present invention, an active material composition for a rechargeable lithium battery, comprising an active material and the binder composition of the present invention, is provided. The present invention also provides an electrode comprising the active material composition. In a preferred embodiment of the present invention, an electrode for a rechargeable lithium battery is provided that includes a current collector; and an active material layer disposed on the current collector, wherein the active material layer includes an active material and the binder composition of the present invention.

[0010] According to yet another aspect of the present invention, a rechargeable lithium battery including a positive electrode, a negative electrode, and an electrolyte is provided, wherein at least one of the positive electrode and the negative electrode comprise the binder of the present invention.

[0011] The cation preferably includes an alkali metal cation, preferably Li⁺, Na⁺, K⁺, or NH₄⁺, or a combination thereof.

[0012] The binder composition preferably has a pH of about 4 to about 14, more preferably about 4 to about 12, more preferably about 6 to about 8.

[0013] The binder composition of the present invention is preferably produced by a process comprising the step of dissolving polyacrylic acid, a hydroxide compound where the cation of the hydroxide compound is an alkali metal or ammonium cation, and polyvinyl alcohol in water to prepare an aqueous mixture. In a preferred embodiment of the present invention the binder composition is produced by a process comprising the steps of: dissolving polyacrylic acid in water; adding a hydroxide compound where the cation of the hydroxide compound is an alkali metal or ammonium cation to form a modified polyacrylic acid comprising one or more acid groups that are substituted with the alkali metal cation or ammonium cation; and adding polyvinyl alcohol to prepare an aqueous mixture.

[0014] In a preferred embodiment of the present invention the polyacrylic acid, the hydroxide compound and the polyvinyl alcohol are combined in the following weight percentages based on the combined weight of these components: polyacrylic acid - about 10% to about 30%, more preferably about 15% to about 25%; hydroxide compound - about 1% to about 15%, more preferably about 2% to about 10%; and polyvinyl alcohol - about 65% to about 85%, more preferably about 70% to about 80%.

[0015] The electrode is preferably a negative electrode and the active material is preferably a negative active material. The negative active material preferably includes a Si-based compound such as Si, SiO_x (0 < x < 2), Si-Q alloy (wherein Q is selected from an alkali metal, an alkaline-earth metal, a group 13 element, a group 14 element, a group 15 element, a group 16 element, a transition element, a rare earth element, or combinations thereof, and is not Si), a Si-C composite, or combinations thereof; a Sn-based compound such as Sn, SnO₂, a Sn-Q¹ alloy (wherein Q¹ is selected from an alkali metal, an alkaline-earth metal, a group 13 element, a group 14 element, a group 15 element, a group 16 element, a transition element, a rare earth element, or combinations thereof, and is not Sn), or combinations thereof.

[0016] The binder composition preferably has a cross-linking ratio of about 0.1 % to about 70 %, more preferably about 15% to about 40%.

[0017] The binder composition preferably has a viscosity range from about 1 Pa.s to about 100 Pa.s.

[0018] Hereinafter, further embodiments will be described in detail.

[0019] When the binder composition according to one embodiment is used for a rechargeable lithium battery, it may improve the stability of an electrode and provide excellent cycle-life characteristics for a battery.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] FIG. 1 is a schematic view of a rechargeable lithium battery according to one embodiment of the present invention.

[0021] FIG. 2 is an IR spectrum of binder compositions obtained from Examples 1 and 3 and Comparative Example 1.

[0022] FIG. 3 is a graph showing a cycle-life characteristic of each rechargeable lithium battery obtained from Examples 4 and 5 and Comparative Example 2.

[0023] FIG. 4 is a flow chart showing the preparation of a cross-linked compound according to one embodiment of the invention.

[0024] FIG. 5 shows the preparation of a cross-linked compound according an embodiment of the invention.

DETAILED DESCRIPTION

[0025] Embodiments of the present invention will hereinafter be described in detail. However, the present invention is not limited thereto.

[0026] The binder composition for a rechargeable lithium battery according to one embodiment includes a cross-linked composition of polyacrylic acid and polyvinyl alcohol, wherein the polyacrylic acid comprises one or more non-cross-linked acid groups that are substituted with an alkali metal or ammonium cation or combinations thereof.

[0027] The cross-linked compound of polyacrylic acid and polyvinyl alcohol is preferably obtained by heating polyacrylic acid and polyvinyl alcohol to effect a cross-linking reaction via esterification.

[0028] According to one embodiment, the cross-linking compound uses a modified polyacrylic acid. The modified polyacrylic acid has a structure where one or more hydroxyl groups of the polyacrylic acid are substituted with an alkali metal cation or ammonium.

[0029] The binder of the present invention provides a rechargeable lithium battery with excellent performance.

[0030] For example, the cross-linked compound according to the present invention may be obtained by the following two embodiments. According to the first embodiment, polyacrylic acid is modified using a hydroxide compound including an alkali metal cation or ammonium cation and the resulting modified polyacrylic acid mixed with polyvinyl alcohol to provide a cross-linked compound of polyacrylic acid, substituted with cation of the hydroxide compound, and polyvinyl alcohol, as shown in Fig. 4.

[0031] In an embodiment of the present invention the polyacrylic acid preferably has a weight-average molecular weight of about 13000 to about 23000. In another embodiment the polyacrylic acid preferably has a glass transition temperature (Tg) of about 100°C to about 112°C. Preferably, the polyacrylic acid has a molecular weight and a glass transition temperature within both the above ranges. In an embodiment of the present invention the polyvinyl alcohol preferably has weight-average molecular weight of about 45000 ± (20,000 to 23,000), e.g. from 22000 to 68000, from 25000 to 65000. In another embodiment the polyvinyl alcohol preferably has a glass transition temperature (Tg) of about 75°C to about 85°C. Preferably, the polyvinyl alcohol has a molecular weight and a glass transition temperature within both the above ranges.

[0032] Preferably, the binder is prepared by a method comprising the steps of: dissolving polyacrylic acid in water; adding a hydroxide compound where the cation of the hydroxide compound is an alkali metal or ammonium to form a modified polyacrylic acid comprising one or more acid groups that are substituted with the alkali metal cation or ammonium cation; and adding polyvinyl alcohol to prepare an aqueous mixture.

[0033] According to the second embodiment, polyacrylic acid, polyvinyl alcohol, and hydroxide compound including alkali cation are mixed together to provide a cross-linked compound of polyacrylic acid substituted with an alkali cation and polyvinyl alcohol, as shown in Fig. 5. Preferably, the binder is prepared by a method comprising the step of dissolving polyacrylic acid, a hydroxide compound where the cation of the hydroxide compound is an alkali metal or ammonium cation, and polyvinyl alcohol in water to prepare an aqueous mixture.

[0034] According to the first and second embodiments, polyacrylic acid is preferably used in the form of an aqueous solution. Preferably, the polyacrylic acid is present in a weight concentration of between about 2% and about 25% based on the weight of the polyacrylic acid and the water, more preferably between about 5% and about 15%. The polyacrylic acid exhibits acidic properties having about pH 3.5 and low viscosity and is clear fluid when it is dissolved in water. The polyacrylic acid is believed to be present in the form of a coil in the aqueous solution. The hydroxide compound is added to the polyacrylic acid aqueous solution to increase pH, so that hydroxyl groups present in the polyacrylic acid are substituted with an alkali metal cation or ammonium cation. Thereby, it is believed that the polyacrylic acid present as a coil form becomes stretched out.

[0035] In this case, the pH of a binder composition is dependent upon the amount of hydroxide compound that is used.

[0036] The polyacrylic acid substituted with the above-mentioned cations has an increased ionization ratio over unmodified polyacrylic acid. Thereby, it more easily performs the cross-linking reaction with polyvinyl alcohol to provide a cross-linked compound, so that the cross-linking ratio is increased.

[0037] The cross-linked compound is preferably obtained by heating the mixed solution to be cross-linked. The heat treatment is preferably performed at a temperature of about 150°C to about 250°C, more preferably about 160°C to about 225°C, or more preferably, at about 180°C to about 200°C for about 30 minutes to about 180 minutes, preferably about 45 minutes to about 120 minutes, more preferably, for example, for about 60 minutes to about 90 minutes. When the heat treatment is performed within the above temperature and time ranges, a cross-linked compound with a high cross-linking ratio is provided.

[0038] In a preferred embodiment of the present invention the polyacrylic acid, the hydroxide compound and the polyvinyl alcohol are combined in the following weight percentages based on the combined weight of these components: polyacrylic acid - about 10% to about 30%, more preferably about 15% to about 25%; hydroxide compound - about 1% to about 15%, more preferably about 2% to about 10%; and polyvinyl alcohol - about 65% to about 85%, more preferably about 70% to about 80%. Preferably, the components are combined in amounts of about 15% to about 25% polyacrylic acid, about 2% to about 10% hydroxide compound and about 70% to about 80% polyvinyl alcohol.

[0039] The cation preferably includes Li⁺, Na⁺, K⁺, NH₄⁺, or a combination thereof.

[0040] The polyacrylic acid substituted with the above-mentioned cations preferably has a substitution ratio of about 100% or less, preferably 99% or less, for example, of about 40% to about 100%, preferably of about 60% to about 99%, more preferably about 80% to about 99%, more preferably about 80% to about 90%. When it has these substitution ratios, a cross-linked compound with a high cross-linking ratio is provided.

[0041] The binder composition preferably has a pH of about 4 to about 14, more preferably about 4 to about 12, more preferably about 6 to about 8. When the binder composition has pH within these ranges, the viscosity of a binder composition is increased to improve the phase stability, thereby the cycle-life characteristics of a rechargeable lithium battery are improved.

[0042] The viscosity of binder composition preferably is in the range from about 1 to about 100 Pa·s, preferably about 3 to 20 Pa·s, more preferably about 4 to 10 Pa·s, most preferably about 5 to about 8 Pa·s at a shearing rate of 1.0 s^-1. When the binder composition has the viscosity within the above ranges, the phase stability is improved, so that the cycle-life characteristics of a rechargeable lithium battery are improved.

[0043] The binder composition preferably has a cross-linking ratio ranging from about 0.1% to about 70%, preferably about 20% to about 60%, preferably about 15% to about 40%. For example, such cross-linking may be obtained under the heating condition of about 200°C and about 60 minutes. The cross-linidng ratio may be measured and calculated through acid-base titration, and the cross-linking may also be obtained by comparing the spectrum size to each functional group though IR analysis. When the cross-linking ratio is within the above ranges, the binding property of an electrode is increased, and the cycle-life characteristics of a rechargeable lithium battery are improved.

[0044] The binder composition optionally further includes a water-soluble binder such as polyvinyl alcohol, carboxylmethyl cellulose, hydroxypropyl cellulose, a polymer including ethylene oxide, and the like, besides the cross-linked compound of the present invention.

[0045] The binder composition may useful to prepare an electrode such as a positive electrode or a negative electrode. Preferably, the binder composition may used in order to prepare the negative electrode.

[0046] The present invention provides an active material composition for a rechargeable lithium battery, comprising an active material and the binder composition of the present invention. The active material composition of the present invention preferably contains between about 1% and about 30% by weight of the binder composition based on the total weight of the active material composition, more preferably between about 5% and about 15%. Preferably, the active material composition comprises between about 65% and about 95% by weight of the active material based on the total weight of the active material composition, more preferably between about 75% and about 85%. Optionally, the compositions further comprises between about 1% and about 30% by weight of a conductive material based on the total weight of the active material composition, preferably between about 1% and about 15%, between about 1% and about 10% and between about 5% and about 10%.

[0047] The present invention also provides an electrode for a rechargeable lithium battery. In a preferred embodiment of the present invention, an electrode for a rechargeable lithium battery is provided that includes a current collector; and an active material layer disposed on the current collector, wherein the active material layer includes an active material, and the binder composition of the present invention. In one embodiment of the present invention, the electrode may be fabricated by mixing an active material and the binder composition including a cross-linked composition of polyacrylic acid and polyvinyl alcohol, wherein the polyacrylic acid comprises one or more non-cross-linked acid groups that are substituted with an alkali metal cation or ammonium cation or combinations thereof, in a solvent to prepare an active material composition, and coating the active material composition on a current collector. Alternatively, the electrode may be fabricated by mixing an active material, the polyacrylic acid and polyvinyl alcohol, wherein the polyacrylic acid comprises one or more non-cross-linked acid groups that are substituted with an alkali metal cation or ammonium cation or combinations thereof, in a solvent to prepare an active material composition, coating the active material composition on a current collector, drying it, followed by heating it. During the heat-treatment, the cross-linkage of modified polyacrylic acid and polyvinyl occurs. Accordingly, in this embodiment, in the fabrication, polyacrylic acid, polyvinyl alcohol and hydroxide compound including alkali cation are used, instead of the modified polyacrylic acid. The heat treatment may be preferably performed at a temperature of about 150°C to about 250°C, more preferably about 160°C to about 225°C, or more preferably, at about 180°C to about 200°C. The heat treatment may be performed for about 30 minutes to about 180 minutes, preferably about 45 minutes to about 120 minutes, more preferably, for example, for about 60 minutes to about 90 minutes.

[0048] According to another embodiment, an electrode and rechargeable lithium battery including the binder composition of the present invention is provided.

[0049] Rechargeable lithium batteries may be classified into lithium ion batteries, lithium ion polymer batteries, and lithium polymer batteries according to the presence of a separator and the kind of electrolyte used in the battery. The rechargeable lithium batteries may have a variety of shapes and sizes, and include cylindrical, prismatic, or coin-type batteries, and may be thin film batteries or may be rather bulky in size. Structures and fabrication methods for lithium ion batteries are well known in the art.

[0050] FIG. 1 is a schematic view of a rechargeable lithium battery according to one embodiment of the present invention. As shown in FIG. 1, the rechargeable lithium battery 100 may be formed with a cylindrical shape and includes a negative electrode 112, a positive electrode 114, a separator 113 disposed between the negative electrode 112 and the positive electrode 114, an electrolyte (not shown) impregnated in the negative electrode 112, the positive electrode 114 and the separator 113, a battery case 120, and sealing member 140 sealing the battery case 120. The rechargeable lithium battery 100 is fabricated by sequentially stacking a negative electrode 112, separator 113, and a positive electrode 114, and spiral-winding them and housing the wound product in the battery case 120.

[0051] The negative electrode includes a current collector and a negative active material layer disposed on the current collector. The negative active material layer includes a negative active material and binder.

[0052] The current collector is preferably selected from the group consisting of a copper film, a nickel film, a stainless steel film, a titanium film, a nickel foam, a copper foam, a polymer substrate coated with a conductive metal, and combinations thereof.

[0053] The negative active material is preferably selected from the group consisting of a material that may reversibly intercalate/deintercalate lithium ions (preferably a carbon material), a lithium metal, a lithium metal alloy, a material that may be doped and dedoped with lithium, a transition metal oxide, and combinations thereof.

[0054] The carbon material that may reversibly intercalate/deintercalate lithium ions preferably includes any carbon-based negative active material generally used in a lithium ion secondary battery, for example, crystalline carbon, amorphous carbon, or a combination thereof. The crystalline carbon preferably includes at least one of shapeless graphite, sheet-type graphite, flake-type graphite, spherical-shaped graphite or fiber-shaped natural graphite, artificial graphite, and mixtures thereof. The amorphous carbon preferably includes soft carbon or hard carbon, mesophase pitch carbide, fired cokes, or mixtures thereof.

[0055] The lithium metal alloy preferably includes lithium metal with a metal selected from the group consisting of Na, K, Rb, Cs, Fr, Be, Mg, Ca, Sr, Si, Sb, Pb, In, Zn, Ba, Ra, Ge, Al, and Sn.

[0056] The material doped and dedoped with lithium preferably includes a Si-based compound such as Si, SiO_x (0 < x < 2), Si-Q alloy (wherein Q is selected from an alkali metal, an alkaline-earth metal, a group 13 element, a group 14 element, a group 15 element, a group 16 element, a transition element, a rare earth element, or combinations thereof, and is not Si), a Si-C composite, or combinations thereof; a Sn-based compound such as Sn, SnO₂, a Sn-Q¹ alloy (wherein Q¹ is selected from an alkali metal, an alkaline-earth metal, a group 13 element, a group 14 element, a group 15 element, a group 16 element, a transition element, a rare earth element, or combinations thereof, and is not Sn), or combinations thereof. The elements Q and Q¹ may be independently selected from the group consisting of Mg, Ca, Sr, Ba, Ra, Sc, Y, Ti, Zr, Hf, Rf, V, Nb, Ta, Db, Cr, Mo, W, Sg, Tc, Re, Bh, Fe, Pb, Ru, Os, Hs, Rh, Ir, Pd, Pt, Cu, Ag, Au, Zn, Cd, B, Al, Ga, Sn, In, Ti, Ge, P, As, Sb, Bi, S, Se, Te, Po, and combinations thereof.

[0057] The transition metal oxide is preferably vanadium oxide, lithium vanadium oxide, and the like.

[0058] When the Si-based compound or the Sn-based compound is used as a negative active material, the binder composition according to the present invention improves the cycle-life characteristics of a rechargeable lithium battery by reducing the deterioration due to the repeated expansion and shrinkage of the negative active material during the charge and discharge.

[0059] The negative active material layer preferably includes a conductive material.

[0060] The conductive material is included to improve electrode conductivity. Any electrically conductive material may be used as a conductive material unless it causes a chemical change. Examples of the conductive material include natural graphite, artificial graphite, carbon black, acetylene black, ketjen black, carbon fiber, a metal powder or a metal fiber including copper, nickel, aluminium, silver, and polyphenylene derivatives.

[0061] The positive electrode 114 includes a current collector and a positive active material layer disposed on the current collector. The positive active material layer includes a positive active material and a binder.

[0062] The current collector is preferably aluminium (Al) but is not limited thereto.

[0063] The positive active material includes a lithiated intercalation compound that reversibly intercalates and deintercalates lithium ions. The positive active material preferably includes a composite oxide including at least one selected from the group consisting of cobalt, manganese, and nickel, as well as lithium. In particular, the following lithium-containing compounds are preferably used.

[0064] Li_aA_1-bR_bD₂ (0.90 ≤ a ≤ 1.8, 0 ≤ b ≤ 0.5); Li_aE_1-bR_bO_2-cD_c (0.90 ≤ a ≤ 1.8, 0 ≤ b ≤ 0.5, and 0 ≤ c ≤ 0.05); Li_aE_2-bR_bO_4-cD_c (0.90 ≤ a ≤ 1.8, 0 ≤ b ≤ 0.5 and 0 ≤ c ≤ 0.05); Li_aNi_1-b-cCo_bR_cD_α(0.90 ≤ a ≤1.8, 0 ≤ b ≤ 0.5, 0 ≤ c ≤ 0.05, and 0 < α ≤ 2); Li_aNi_1-b-cCo_bR_cO_2-αZ_α(0.90 ≤ a ≤ 1.8, 0 ≤ b ≤ 0.5, 0 ≤ c ≤ 0.05, and 0 < α < 2); Li_aNi_1-b-cCo_bR_cO_2-αZ₂(0.90 ≤ a ≤ 1.8, 0 ≤ b ≤ 0.5, 0 ≤ c ≤ 0.05, and 0 < α < 2); Li_aNi_1-b-cMn_bR_cD_α (0.90 ≤ a ≤ 1.8, 0 ≤ b ≤ 0.5, 0 ≤ c ≤ 0.05, and 0 < a ≤ 2); Li_aNi_1-b-cMn_bR_cO_{2- α}Z_α (0.90 ≤ a ≤ 1.8, 0 ≤ b ≤ 0.5, 0 ≤ c ≤ 0.05, and 0 < α < 2); Li_aNi_1-b-cMn_bR_cO_2-αZ₂ (0.90 ≤ a ≤ 1.8, 0 ≤ b ≤ 0.5, 0 ≤ c ≤ 0.05, and 0 < α < 2); Li_aNi_bE_cG_dO₂ (0.90 ≤ a ≤ 1.8, 0 ≤ b ≤ 0.9, 0 ≤ c ≤ 0.5, and 0.001 ≤ d ≤ 0.1); Li_aNi_bCo_cMn_dG_eO₂ (0.90 ≤ a ≤ 1.8, 0 ≤ b ≤ 0.9, 0 ≤ c ≤ 0.5, 0 ≤ d ≤ 0.5, and 0.001 ≤ e ≤ 0.1); Li_aNiG_bO₂ (0.90 ≤ a ≤ 1.8, and 0.001 ≤ b ≤ 0.1); Li_aCoG_bO₂ (0.90 ≤ a ≤ 1.8 and 0.001 ≤ b ≤ 0.1); Li_aMnG_bO₂ (0.90 ≤ a ≤ 1.8 and 0.001 ≤ b ≤ 0.1); Li_aMn₂G_bO₄ (0.90 ≤ a ≤ 1.8 and 0.001 ≤ b ≤ 0.1); QO₂; QS₂; LiQS₂; V₂O₅; LiV₂O₅; LiZO₂; LiNiVO₄; Li_(3-f)J₂(PO₄)₃ (0 ≤ f ≤ 2); Li_(3-f)Fe₂(PO₄)₃ (0 ≤ f ≤ 2); and LiFePO₄.

[0065] In the above formulae, A is selected from Ni, Co, Mn, and a combination thereof; R is selected from Al, Ni, Co, Mn, Cr, Fe, Mg, Sr, V, a rare earth element, and a combination thereof; D is selected from O, F, S, P, and a combination thereof; E is selected from Co, Mn, and a combination thereof; Z is selected from F, S, P, and a combination thereof; G is selected from Al, Cr, Mn, Fe, Mg, La, Ce, Sr, V, and a combination thereof; Q is selected from Ti, Mo, Mn, and a combination thereof; and J is selected from V, Cr, Mn, Co, Ni, Cu, and a combination thereof.

[0066] The compound optionally has a coating layer on the surface, or is optionally mixed with another compound having a coating layer. The coating layer preferably includes at least one coating element compound selected from the group consisting of an oxide of a coating element, a hydroxide of a coating element, an oxyhydroxide of a coating element, an oxycarbonate of a coating element, and a hydroxyl carbonate of a coating element. The compound for the coating layer may be amorphous or crystalline. The coating element included in the coating layer preferably includes Mg, Al, Co, K, Na, Ca, Si, Ti, V, Sn, Ge, Ga, B, As, Zr, or mixtures thereof. The coating layer may be disposed in a method having no adverse influence on properties of a positive active material by using these elements in the compound. For example, the method may include any coating method such as spray coating, dipping, and the like, but is not illustrated in more detail since it is well-known to those who work in the field.

[0067] If an electrode is present that does not contain the binder of the present invention, the binder used is preferably selected from the group including polyvinylidene fluoride (PVDF), polyimide, polyamideimide, polyvinylalcohol, carboxylmethylcellulose, hydroxypropylcellulose, diacetylcellulose, polyvinylchloride, carboxylated polyvinylchloride, polyvinylfluoride, an ethylene oxide-containing polymer, polyvinylpyrrolidone, polyurethane, polytetrafluoroethylene, polyethylene, polypropylene, a styrene-butadiene rubber, an acrylated styrene-butadiene rubber, an epoxy resin, nylon, and the like, but are not limited thereto.

[0068] The positive active material layer preferably selectively includes conductive material.

[0069] The conductive material is included to improve electrode conductivity. Any electrically conductive material may be used as a conductive material unless it causes a chemical change. Examples of the conductive material include one or more of natural graphite, artificial graphite, carbon black, acetylene black, ketjen black, carbon fiber, a metal powder or a metal fiber including copper, nickel, aluminium, silver, and polyphenylene derivatives.

[0070] The negative 112 and positive electrodes 114 may optionally be fabricated by a method including mixing the active material, a conductive material, and a binder in a solvent, into an active material composition and coating the composition on a current collector. The electrode manufacturing method is well known, and thus is not described in detail in the present specification. The solvent for the positive electrode may be N-methylpyrrolidone, but it is not limited thereto. The solvent for the negative electrode may be water, but is not limited thereto.

[0071] The electrolyte includes a lithium salt and a non-aqueous organic solvent.

[0072] The lithium salt is dissolved in an organic solvent and plays a role of supplying lithium ions in a battery, operating a basic operation of the rechargeable lithium battery, and improving lithium ion transportation between positive and negative electrodes therein.

[0073] Non-limiting examples of the lithium salt include LiPF₆, LiBF₄, LiSbF₆, LiAsF₆, LiN(SO₂C₂F₅)₂, Li(CF₃SO₂)₂N, LiN(SO₃C₂F₅)₂, LiC₄F₉SO₃, LiClO₄, LiAlO₂, LiAlCl₄, LiN(CF_2x+1SO₂)(C_yF_2y+1SO₂) (x and y are natural numbers), LiCl, LiI, and LiB(C₂O₄)₂ (lithium bis(oxalato) borate; LiBOB). The lithium salt may be used in a concentration ranging from about 0.1 M to about 2.0 M. When the lithium salt is included at the above concentration range, an electrolyte may have excellent performance and lithium ion mobility due to optimal electrolyte conductivity and viscosity.

[0074] The non-aqueous organic solvent serves as a medium for transmitting ions taking part in the electrochemical reaction of a battery.

[0075] The non-aqueous organic solvent preferably includes a carbonate-based, ester-based, ether-based, ketone-based, alcohol-based, or aprotic solvent.

[0076] Examples of the carbonate-based solvent preferably includes dimethyl carbonate (DMC), diethyl carbonate (DEC), dipropyl carbonate (DPC), methylpropyl carbonate (MPC), ethylpropyl carbonate (EPC), methylethyl carbonate (MEC), ethylmethyl carbonate (EMC), ethylene carbonate (EC), propylene carbonate (PC), butylene carbonate (BC), or the like.

[0077] When the carbonate-based solvent is prepared by mixing a cyclic carbonate and a chain carbonate, a solvent having a low viscosity while having an increased dielectric constant may be provided. The cyclic carbonate and the chain carbonate are mixed together in a volume ratio of about 1:1 to about 1:9.

[0078] Examples of the ester-based solvent preferably include methyl acetate, ethyl acetate, n-propyl acetate, dimethylacetate, methylpropionate, ethylpropionate, γ-butyrolactone, decanolide, valerolactone, mevalonolactone, caprolactone, or the like. Examples of the ether-based solvent include dibutyl ether, tetraglyme, diglyme, dimethoxyethane, 2-methyltetrahydrofuran, tetrahydrofuran, or the like, and examples of the ketone-based solvent include cyclohexanone, or the like. Examples of the alcohol-based solvent include ethyl alcohol, isopropyl alcohol, and the like, and examples of the aprotic solvent include nitriles such as R-CN (where R is a C2 to C20 linear, branched, or cyclic hydrocarbon, a double bond, an aromatic ring, or an ether bond), amides such as dimethylformamide, dioxolanes such as 1,3-dioxolane, sulfolanes, or the like.

[0079] The non-aqueous organic solvent may be used singularly or in a mixture. When the organic solvent is used in a mixture, the mixture ratio may be controlled in accordance with a desirable battery performance.

[0080] The non-aqueous electrolyte optionally further includes an overcharge-inhibiting additive such as ethylenecarbonate, pyrocarbonate, and the like.

[0081] Non-limiting examples of the separator 113 include polyethylene, polypropylene, polyvinylidene fluoride, and multi-layers thereof such as a polyethylene/polypropylene double-layered separator, a polyethylene/polypropylene/polyethylene triple-layered separator, and a polypropylene/polyethylene/polypropylene triple-layered separator.

[0082] Hereinafter, the embodiments are illustrated in more detail with reference to examples. However, the following are merely embodiments of the present invention and are not limiting.

[0083] Furthermore, what is not described in this specification can be sufficiently understood by those who have knowledge in this field and will not be illustrated here.

<Preparation of binder composition>

Example 1

[0084] 18 wt% of a polyacrylic acid aqueous solution (10 wt% concentration), 8 wt% of NaOH, and 74 wt% of polyvinyl alcohol are mixed and heated at 200°C for 60 minutes to provide a binder composition of cross-linked compound of Na⁺-substituted polyacrylic acid and polyvinyl alcohol. The substitution ratio was about 90%.

Example 2

[0085] 20 wt% of a polyacrylic acid aqueous solution with a concentration of 10 wt%, 4 wt% of NaOH, and 76 wt% of polyvinyl alcohol are mixed and heated at 200°C for 60 minutes to provide a binder composition of cross-linking compound of Na⁺-substituted polyacrylic acid and polyvinyl alcohol. The substitution ratio was about 50%.

Example 3

[0086] 18 wt% of a polyacrylic acid aqueous solution with a concentration of 10 wt%, 10 wt% of NaOH, and 72 wt% of polyvinyl alcohol are mixed and heated at 200°C for 60 minutes to provide a binder composition of cross-linking compound of Na⁺-substituted polyacrylic acid and polyvinyl alcohol. The substitution ratio was about 100%.

Comparative Example 1

[0087] 20 wt% of a polyacrylic acid aqueous solution with a concentration of 10 wt%, and 80 wt% of polyvinyl alcohol are mixed and heated at 200°C for 60 minutes to provide a binder composition of cross-linking compound of polyacrylic acid and polyvinyl alcohol.

Evaluation 1-1: pH measurement of binder composition

[0088] Each binder composition obtained from Examples 1 to 3 and Comparative Example 1 is measured for pH using a pH meter, and the results are shown in the following Table 1.

Evaluation 1-2: Cross-linking ratio measurement of binder composition

[0089] Each binder composition obtained from Examples 1 to 3 and Comparative Example 1 is measured and calculated for a cross-linking ratio through an acid-base titration, and the results are shown in the following Table 1.

Evaluation 1-3: Viscosity measurement of binder composition

[0090] Each binder composition obtained from Examples 1 to 3 and Comparative Example 1 is measured for viscosity using a rheometer, and the results are shown in the following Table 1.

Table 1

	Examples			Comparative Example 1
	1	2	3
pH	6.3	4.8	11.9	3.4
Cross-linking ratio (%)	44	28	46	18
Viscosity (Pa·s)	5.78	4.50	10.23	2.42

[0091] As shown in Table 1, it is confirmed that Examples 1 to 3 including the cross-linking compounds of polyacrylic acid, substituted with an alkali metal cation, and polyvinyl alcohol have higher pH, cross-linking ratio, and viscosity compared to Comparative Example 1 including the cross-linking composition polyacrylic acid, which is not substituted with alkali metal cation, and polyvinyl alcohol.

[0092] In addition, it is confirmed that the viscosity is also increased along with increasing pH in Examples 1 to 3.

Evaluation 1-4: IR data of binder composition

[0093] FIG. 2 shows an IR spectrum of binder compositions obtained from Examples 1 and 3 and Comparative Example 1.

[0094] Referring to FIG. 2, it is understood that Comparative Example 1 including a cross-linked compound of polyacrylic acid which is not substituted with alkali cation and polyvinyl alcohol shows a peak from carboxyl group of polyacrylic acid at around 1710 cm^-1, on the other hand, Examples 1 and 3 including the cross-linked compound of polyacrylic acid substituted with an alkali cation and polyvinyl alcohol according to one embodiment does not show the peak, or the peak is shifted to around 1600 cm^-1. From the results, it is understood that each binder composition obtained from Examples 1 and 3 is cross-linked.

<Fabrication of rechargeable lithium battery cell>

Example 4

[0095] 80 wt% of a negative active material of a Si/SiO₂/carbon composite, 10 wt% of binder of a binder composition, and 10 wt% of conductive material of carbon black are mixed and dispersed in water to provide a composition for a negative active material layer. The binder composition was prepared by mixing polyacrylic acid aqueous solution (10 wt% concentration), NaOH, and polyvinyl alcohol at a weight ratio of 18 : 8 : 74 weight ratio.

[0096] Subsequently, the composition for a negative active material layer is coated on a Cu-foil current collector, dried and then heat-treated at 200°C for 60 minutes to provide a negative electrode.

[0097] As a counter electrode of the negative electrode, lithium metal is used to provide a coin-type half-cell. An electrolyte is prepared by dissolving 1.3 M of LiPF₆ in a mixed solution of ethylene carbonate (EC) and dimethyl carbonate (DMC) in a volume ratio of 3:7.

Example 5

[0098] A con-type half-cell was fabricated by the same procedure as in Example 4, except that a mixture of polyacrylic acid aqueous solution (10 wt% concentration), NaOH, and polyvinyl alcohol at a weight ratio of 20 : 4 : 76 weight ratio was used as the binder composition.

Example 6

[0099] A con-type half-cell was fabricated by the same procedure as in Example 4, except that a mixture of polyacrylic acid aqueous solution (10 wt% concentration), NaOH, and polyvinyl alcohol at a weight ratio of 18 : 10 : 72 weight ratio was used as the binder composition.

Comparative Example 2

[0100] A con-type half-cell was fabricated by the same procedure as in Example 4, except that a mixture of polyacrylic acid aqueous solution (10 wt% concentration) and polyvinyl alcohol at a weight ratio of 20 : 80 weight ratio was used as the binder composition.

Evaluation 2: Assessment of cycle-life characteristic of rechargeable lithium battery cell

[0101] Each rechargeable lithium battery obtained from Examples 4 to 6 and Comparative Example 2 is assessed for a cycle-life characteristic, and the results are shown in FIG. 3.

[0102] It is charged under the condition of constant current/ constant voltage (CC/CV) mode of 0.02C, 0.2C, 0.5C, and cut off of 0.01C, respectively and discharged under the condition of constant current mode of 0.02C, 0.2C, 0.5C, and cut off 1.4V, respectively.

[0103] FIG. 3 is a graph showing a cycle-life characteristic of each rechargeable lithium battery obtained from Examples 4 and 5 and Comparative Example 2.

[0104] Referring to FIG. 3, it is confirmed that Examples 4 and 5 including a cross-linked compound of polyacrylic acid substituted with an alkali cation and polyvinyl alcohol have superior cycle-life characteristics to Comparative Example 2 including a cross-linking compound of polyacrylic acid which is not substituted with an alkali cation and polyvinyl alcohol.

[0105] While this disclosure has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.

Claims

1. A binder composition for a rechargeable lithium battery, comprising:

a cross-linked composition of polyacrylic acid and polyvinyl alcohol, wherein the polyacrylic acid comprises one or more non-cross-linked acid groups that are substituted with an alkali metal cation or ammonium cation or combinations thereof.

2. The binder composition for a rechargeable lithium battery of claim 1, wherein the cation is selected from the group consisting of Li⁺, Na⁺, K⁺, NH₄⁺, or combinations thereof.

3. The binder composition for a rechargeable lithium battery of claim 1 or claim 2, wherein the binder composition has pH of about 4 to 14, more preferably about 4 to about 12, more preferably about 6 to about 8.

4. The binder composition for a rechargeable lithium battery of any of claims 1 to 3, wherein the binder composition has cross-linking ratio of about 0.1% to about 70 %, preferably about 20% to about 60%, more preferably about 25% to about 50%.

5. The binder composition for a rechargeable lithium battery of any of claims 1 to 4, wherein the binder composition has a viscosity range from about 1 to about 100 Pa·s, preferably about 3 to about 50 Pa·s, more preferably about 4 to about 20 Pa·s.

6. A process for preparing the composition of any of claims 1 to 5 comprising the step of dissolving polyacrylic acid, a hydroxide compound where the cation of the hydroxide compound is an alkali metal or ammonium cation, and polyvinyl alcohol in water to prepare an aqueous mixture.

7. The process of claim 6 further comprising the steps of:

dissolving polyacrylic acid in water;

adding the hydroxide compound to form a modified polyacrylic acid comprising one or more acid groups that are substituted with the alkali metal cation or ammonium cation; and

adding polyvinyl alcohol to prepare an aqueous mixture.

8. The process of either of claims 6 or 7 further comprising the step of heating the aqueous mixture at a temperature of about 150°C to about 250°C, preferably about 160°C to about 225°C, more preferably about 180°C to about 200°C and for a time period of about 30 minutes to about 180 minutes, preferably about 45 minutes to about 120 minutes, more preferably about 60 minutes to about 90 minutes.

9. The process of any of claims 6 to 8, wherein the polyacrylic acid, hydroxide compound and polyvinyl alcohol are combined in the following weight percentages based on the combined weight of these components:

polyacrylic acid - about 10% to about 30%, more preferably about 15% to about 25%;

hydroxide compound - about 1% to about 15%, more preferably about 2% to about 10%; and

polyvinyl alcohol - about 65% to about 85%, more preferably about 70% to about 80%.

10. The process of any of claims 6 to 9, wherein the polyacrylic acid is present in a weight concentration of between about 2% and about 25% based on the weight of the polyacrylic acid and the water, more preferably between about 5% and about 15%.

11. An active material composition for a rechargeable lithium battery, comprising:

an active material and a binder composition as claimed in any of claims 1 to 5.

12. The active material composition of claim 11, wherein the active material is a negative active material.

13. The active material composition of claim 12, wherein the negative active material comprises:

a Si-based compound selected from Si, SiO_x (0 < x < 2), a Si-Q alloy (wherein Q is selected from an alkali metal, an alkaline-earth metal, a group 13 element, a group 14 element, a group 15 element, a group 16 element, a transition element, a rare earth element, or combinations thereof, and is not Si), a Si-C composite, or combinations thereof;

a Sn-based compound selected from Sn, SnO₂, a Sn-Q¹ alloy (wherein Q¹ is selected from an alkali metal, an alkaline-earth metal, a group 13 element, a group 14 element, a group 15 element, a group 16 element, a transition element, a rare earth element, or combinations thereof, and is not Sn), or combinations thereof.

14. An electrode comprising the active material composition of any of claims 11 to 13.

15. A rechargeable lithium battery comprising
a positive electrode;
a negative electrode; and
an electrolyte,
wherein at least one of the positive electrode and the negative electrode is as claimed in claim 14.

Drawing